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Medical 3D Printing

Our medical models are “carbon copies” of the refined DICOM data from CT/MRI scans. The materials used and special finishing processes allow surgeons to carry out pre-operative planning. The models provide accurate visualisation of anatomy including fragment position. They allow planning of surgery to include implants required and pre-bending of implants. The use of models has been shown to decrease surgery and aneasthetic times and allows the surgeon to make smaller and more accurate localised incisions. This may lead to a decrease in patient length of stay. Models can also be used as an effective aid when explaining the operation to a patient.

Replica 3dm models help in the identification of correct surgery rental kits saving up to 25% on unused kits as surgeons are able to pre-fit, drill and tap models during pre-operative planning. A recent hip revision model which cost around £600 was able to reduce the overal procedural cost by an estimated £3,500 [see case reports below].

Turnaround Times
At Replica 3dm we have experience in producing models for Maxillofacial, Orthopeadics, ENT, and Plastics Departments. On receipt of a CT scan we produce a quote within 72 hours and turnaround a model within 5 working days of receiving quote confirmation. Urgent models can be initiated for print within hours of receipt of a CT. Elective surgery models go into our 2 week window print queues where urgency isn't such an issue.

Supplying CT information
CT scans can be sent to Replica 3dm via the PACS service using IEP protocols within the NHS. Other medical institutions can use encrypted CDs or our secure server transfer.

Please contact Replica 3dm to discuss CT image transfer in detail.

Ordering a medical model (NHS only).

PACS Form download
Return Email Address for PACS form

Sample interactive models

This model required the cranium to be extracted from the CT isolating the area of interest to show the patient skull contours. The defect was re-contoured for asthetics. The model was 3D printed and delivered to the Maxillofacial Lab at Salisbury District Hospital for the titanium plate to be fitted using the 3D printed model.

Cranioplasty 3D Printed Model

Cranioplasty by replica3dm on Sketchfab

Mandible 3D Printed Model
This is common model for Replica 3dm. A Mandible model was required for a patient specific pre-operative titanium plate bending.

Mandible by replica3dm on Sketchfab

Maxilla 3D Printed Model
A maxilla model is generally for facial reconstructions. The required area is isolated and 3D printed ready for the surgeon to carry out a pre-operative investigation and plate bending.

Maxilla by replica3dm on Sketchfab

Hip Revision 3D Printed Model
Complicated hip revision surgery can benefit from 3D print models. The model allows the surgeon to carry out a detail pre-operative investigation, fit cups and test for alignment / fixing (see our case reports below for an example.

Hip Revision Model by replica3dm on Sketchfab

Our Software / Hardware

We use Stratasys Objet24 and a PLA printer, these are industry standard for medical applications due to the high resolution, accuracy and material used which is preferable to maxillofacial labs. Both printers have CE/FCC/RoHS regulatory compliance.

Our software applications use the latest developments in 3D geodesic active contour and region competition algorithms for acquiring a 3D mesh from a 2D CT scan. These methods provide accurate contouring of isolated threshold values in CT’s. Our medical software is approved by The Centre for Medical Image Computing (UCL).

Models are routinely tested for accuracy by comparing the CT against printed models taking measurements from both.

Medical Case Reports

Replica 3dm requests that surgeons carrying out complicated or unsual procedures where a Replica 3dm model has been supplied that they produce a case report. The case report provides valuable information regarding the procedure, the benefits of a model and the patient outcome. This information is then passed to other surgeaons on our client base to further improve patient care.


An innovation leader specialising in high resolution medical and commercial 3D printing. Replica 3dm produce models for many different applications across a wide range of industries.

Our service is revolutionising how surgeons approach the operating theatre and is changing the face of product engineering and architectural design development.

Laing Building,
Salisbury District Hospital
Odstock Road
Salisbury SP2 8BJ
United Kingdom

Phone: +44 (0)1722 439 553


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